Which Chain Specifications Are Suitable for The Chain Remover?

Chain maintenance is essential in power transmission as it helps in the smooth running of power transmission systems. A chain remover (chain breaker or chain splitting tool) is specifically made to serve this purpose. However, using the correct tool depends on knowing the chain specifications involved.

This article will explore the chain specifications suitable for the chain remover to help you make the right choice.

What is a Chain Remover?

A chain remover is a special device that is designed to shrink chains by forcing the connecting pin out of the chain link. It works through a simple yet precise mechanical process, consisting of a threaded needle that drives a pin through the chain's rivet pin, separating the link without damaging the rollers.

This system maximizes the ability to repair, adjust, or replace the chain within a short time.

Types of Chain Remover

1. Manual chain removers: These removers are small and can be operated by a screw driven pin, which forces the chain pin out of the link as the chain is held in a shaped cradle.

2. Bench-mounted or table chain removers: These chain removers use a screw-press style to drive a pin punch with higher mechanical advantage and stability. It is able to make better alignment in medium-duty applications, e.g., in conveyors and industrial drives.

3. Hydraulic chain removers: These chain removers use hydraulic pressure to force the pin punch. They are used for automotive or large conveyor chains. They often come as portable hydraulic units or are integrated into hydraulic maintenance rigs.

4. Pneumatic or Air-driven removers: Pneumatic chain removers have compressed air to push the pin. They can be used in large volume applications where speed is very important.

5. Electric/Motorized Chain Removers: These are motorized chain removers or automatic splitters that have an electric motor that powers the punch.

6. Press Chain Removers: Press chain removers are general-purpose removers with custom tooling to remove pins from unusual or heavy chains.  

Specialized Tools and Accessories for Chain Remover

• Pin extractors/punches: They are replaceable hardened pins that press out of the chain pin.

• Chain pullers or tensioners: These are equipment used to put the chain in a position to remove it.

• Master link pliers and riveting tools: Master link pliers are applied to open or close quick links, and riveting tools are applied to deform rivet heads in the right manner on the motorcycle chain.

• Chain vises, jigs, and fixtures: These are used to keep the chain in the correct position during the punch action.

Key Chain Specifications that Affect Compatibility

Chain Pitch

One of the most sensitive specifications that influences the compatibility with the chain remover is the chain pitch. The chain pitch refers to the distance between the centers of two pins in a chain. The chain pitch determines the overall size, load-carrying capacity, and gaps between the components in the chain.

The standard roller chains common pitches in ANSI (American National Standards Institute) are 1 inch, 3/8 inch, 1/2 inch, 3/4 inch, 3/8 inch, and 3/6 inch. In the case of metric chains, the pitches of ISO standards are in millimeters, e.g., 12.7mm or 15.875mm.

The cradle, anvil, and punch of a chain remover are all calculated to fit a particular range of pitch. When the chain pitch is too large in relation to the tool, the chain will fail to fit into place, and the punch might hit the link out of center. This may result in crooked pins or fractured plates. Conversely, a chain pitch that is too small might not be able to track the pin centerline.

Roller Diameter

The roller chain's diameter indicates how the chain sits inside the remover's support channel and how the load is evenly distributed during pin extraction. Each chain link has rollers that rotate over sprocket teeth, and these rollers must fit perfectly in the tool's seat when applying force. If the roller diameter is larger than expected, the chain may not settle evenly. If it is smaller, the chain might shift during operation.

For ANSI chains, the roller diameter ranges from 0.130 inches on #25 chains to 0.625 inches on #80 chains, while ISO chains may have a slight range. Measuring the roller diameter with precision calipers is necessary before using a remover, especially in heavy-duty applications like conveyor systems or power drives. A mismatch between roller size and tool seating results can lead to inefficient force transmission, damaging the chain or the punch tip.

Inner Width and Pin Diameter

The inner width refers to the space between the inner plates. This is what defines how the chain mates with sprockets and how it seats in a chain remover. A chain remover must allow enough clearance to accommodate the inner width while securing the chain in position. For instance, an ANSI #40 chain has an inner width of about 0.312 inches, while a #60 chain has an inner width of 0.469 inches. A mismatch means that the chain won’t fit in the cradle or will wobble.

The pin diameter is also important, as this is what dictates the correct punch tip size for the remover. The pin connects the inner and outer plates and bears the tensile load. If the punch is too narrow compared to the pin, it may slip off, deforming the pin head and damaging the tool. On the other hand, if it is too wide, it may press against the link plates, causing cracks or misalignments.

Chain Standards

Chains used in power transmission systems are governed by various international standards that define their dimensions and tolerances. The most recognized standards are ANSI, ISO, and DIN. Each of these standards specifies parameters like chain pitch, roller diameter, and pin length - all of which determine compatibility with a chain remover.

ANSI standard roller chains follow the ⅛-inch pitch progression, that is, #25 = ¼, #40 = ½, #80 = 1. Most chain removers are built around ANSI dimensions. In Europe, ISO and DIN chains are mostly used in industrial applications, with metric pitches and slightly different roller profiles.  

While these standards are similar, an ISO chain may not fit perfectly in an ANSI-specific tool due to minor dimensional differences. A minor difference can misalign the punch.

How to Select the Right Tool for Chain Remover

Identify your chain

The first step is to identify your chain type. Chains are often designed according to different standards, such as ANSI, ISO, or DIN, and each of these standards has its own pitch and roller dimensions. Check the markings on the chain's side plate with identifiers, like #40 or 08B.

If there are no markings, check the construction. Standard roller chains have cylindrical rollers; bush chains do not have rollers, while conveyor chains may have pins or attachments. Identifying the chain types will ensure the remover's cradle and pin align with the chain's geometry.

Measure the pitch

After identifying the chain type, the next step is to measure the pitch. As mentioned earlier, the pitch is the spacing between link pins and dictates the size of the chain remover you’ll need. You can use a vernier caliper to measure the distance between the centers of two adjacent pins. To get a more accurate measurement, measure across several links and divide the total by the number of pitches.

Each chain remover is designed to fit a specific pitch range. For instance, one tool may handle #25 - #60 chains, while another tool may handle #80 - #100 chains. Selecting a tool outside your pitch range can cause slippage or uneven movement during operation.

You can make a reference to the chart comparing pitch size to chain number to speed up tool selection.

Check tool compatibility

Check if the pin diameter and cradle width are compatible with your chain's design. If the remover pin is too large, it may jam the link plate; if it is too small, it can slip or damage the pin head.

Remember that chain removers come in different types. Each type is optimized for a specific strength range and link configuration. Always verify that the tool’s specification sheet lists your chain series. Check whether replacement pins and anvils are available from your manufacturer.

Consider the application

For light-duty applications, a manual chain remover can be sufficient as it is cost-effective and easy to operate. For industrial chains in continuous operations, a hydraulic or pneumatic chain remover is required to provide the force needed to handle heavy-duty applications.

For field repairs, manual chain removers with hardened steel pins provide on-site servicing without removing the chain from the machine. In corrosive environments, tools that have advanced surface treatments are needed to resist rust and deformation. High-precision systems need bench-mounted chain removers for consistent and reliable operation.

Maintenance Tips for Extended Life

1. Maintain cleanliness and lubrication

• Use a mild degreaser or solvent to regularly clean the chain to remove old lubricant. Wipe the chain dry with a lint-free cloth. Do not use water under high pressure, as it can force contaminants into internal places.

• Apply high-quality chain oil formulated for your chain. Ensure the lubricant penetrates the pin-bushing interface, but take care not to overlubricate, as it can attract debris.

1. Inspect the Chain Remover Regularly

• Regularly inspect the chain remover for visible cracks or deformation on the press pin. These could be signs of fatigue or excessive force application.

• Ensure the threads turn smoothly. Only apply a light lubricant if resistance is felt.

• For hydraulic chain removers, inspect for leaks and ensure pressure gauges are calibrated.

• Replace any worn-out parts immediately.

1. Follow Proper Tool Usage Practices

• For manual chain removers, turn the handle steadily rather than abruptly. A sudden turn can bend the press crews.

• For hydraulic or pneumatic removers, ensure pressure settings do not exceed the specified recommendations.

• Do not use pliers or hammers to assist the remover, as this can cause distortion or tool misalignment.

1. Store Tools and Chains Properly

• Keep your chain remover in a dry, temperature-controlled environment. If it will be unused for long periods, lightly coat the surfaces to protect them.

• Store unused spare chains in a sealed container, avoiding direct exposure to sunlight, chemicals, or moisture.

1. Schedule Preventive Maintenance Intervals

• Inspect high-duty chains every 500 operating hours.

• Inspect threads, pins, and handles weekly on chain removers for daily use.

Conclusion

Selecting the right chain specifications for the chain remover helps to achieve precision, safety, and tool durability. By identifying your chain type and measuring its pitch, you can ensure a perfect fit for a smooth operation.

If you're looking for technical expertise and a reliable solution for power transmission components, then don’t hesitate to contact HANGZHOU PERPETUAL MACHINERY & EQUIPMENT CO., LTD.

FAQs

What type of chain is commonly used in chain drives?

The roller chain is commonly used in chain drives on bicycles and motorcycles. It is known for its efficiency, extended service life, and ability to transfer power through rotating shafts that engage with sprocket teeth, thereby minimizing friction.

What happens if I use the wrong tool for chain removal?

Using the wrong tool for a chain remover can cause serious damage to the chain. It could lead to a weak chain, poor performance, or complete equipment failure. Furthermore, it can cause bent or deformed links, wrecked pins, poor shifting, or accelerated wear.

How often should I inspect or replace my chain remover?

The frequency of inspection depends on the quality of the tool, the frequency of use, and whether it has a replaceable pin. Furthermore, replacing a chain doesn’t need a set mileage. You should inspect it for damage before each use and replace it when it is no longer functioning as it should.

How do I know if my chain remover fits an ANSI #80 chain?

To know if your chain remover fits an ANSI #80 chain, you must check the tool’s specifications and compare it against the key dimensions of an #80 chain.

Which type of chain is used for lifting?

Alloy steel chain slings with Grade 80, Grade 100, or Grade 120 are most suitable for overhead lifting applications.